heat exchanger leak repairs product information guide

8/20/2019 Heat Exchanger Leak Repairs Product Information Guide

1/16

PRODUCT INFORMATION GUIDEHydrostatic Testing and Isolation

Heat Exchanger Testing and Plugging

Heat Exchanger Repair

Plumber’s Tools

Field Services


2/16

EST GROUP

A global manufacturer and designer of pipe and tube pressure

testing and plugging equipment, EST Group is a business unit of

Curtiss-Wright Flow Control Company, headquartered in Hateld,

PA. Since 1968, EST Group has specialized in the development,

manufacturing, and marketing of tools and systems that greatly

simplify the maintenance of shell and tube heat exchangers and

that speed-up the in-service inspection of pipe, pipelines, piping

systems, and pressure vessels. Our plugging systems have saved

our customers millions of dollars in maintenance and downtime.

In 2009, EST Group was acquired by Curtiss-Wright Corporation.

We continue to serve the power generation, upstream oil and gas,

rening, petrochemical, ne chemical and pharmaceutical industries

worldwide.

Quality Assurance System:

Manufactured under QA programcertied to ISO-9001.Can be supplied under ANSI N45.2,10CFR50 Appendix B.

Content

03-04Heat Exchanger Tube Plugs

05Heat Exchanger Tube PlugInstallation & Removal Tools

06-07Heat Exchanger Tube Testers

08EST Field Services

09-13Hydrostatic Test & IsolationPlugs

14

Hydrostatic Test Pumps

15Plumber’s & Specialty Tools


3/16

Pop-A-Plug ® II (P2) A proven long-term performer in fossil and nuclear stations, the P2 features patented internally serrated ringsdesigned to maintain a leak tight seal under extreme thermal and pressure cycling. The P2 tube plugging systemreduces downtime, eliminates welding and explosives, and will not damage your tubes, tubejoints or tubesheet.Pressures to 7,000 psi (480 Bar). Sizes 0.400 ″ to 1.460 ″ (10.16mm to 37.59mm) tube I.D. Proven helium leak tight to1 x 10 -11 cc/sec. It installs quickly and easily, and a controlled installation force eliminates damage to tube joints andepoxy coated tube sheet. Larger and smaller sizes available. Removable for retubing. Manufactured under a qualitysystem that meets ANSI N45.2, 10CFR50 App B, 10CFR21, and certied to ISO9001. U.S. patent number 5,437,310.

Perma Plugs™Perma Plugs™ use proven Pop-A-Plug ® technology to provide a leak tight seal while eliminating the potential ofdamage to tubejoints and tubesheets. Once installed, Perma Plugs™ stay installed until it’s time to retube. Operatingpressures to 1,000 psi (68.9 Bar). Sizes for 0.472 ″ to 2.067 ″ (11.99mm to 52.50mm) tubes. Helium leak tight to1 x 10 -11 cc/sec. Removable for retubing. Designed for the rigors of power plant condensers. No more leaking or lostplugs. A controlled installation force eliminates damage to tube joints and epoxy coated tube sheets. Manufacturedunder a quality system that meets ANSI N45.2, 10CFR50 App B, 10CFR21, and certied to ISO9001. U.S. patentnumber 5,437,310.

HEAT EXCHANGER TUBE PLUGS

EST Group offers Go/No-Go gauges in a variety of sizes to determine the correct plug sizeneeded. Contact Customer Service for more information.

DID YOU

KNOW?800.355.7044


4/16

Unique to EST Group’s Pop-A-Plug ® system, the Through-The-Tube Plugging™procedure allows a tube plug to be passed the length of a straight through-tubeheat exchanger, without having to remove the bundle or far end cover. ContactCustomer Service for more information.

CPI Pop-A-Plug ®

Designed to meet the rigors of the Chemical Process Industries, CPI Pop-A-Plugs ® are resistant to thermal cycling and are able to provide a seal that is helium leak tight.CPI Pop-A-Plugs ® install using a controlled force. This protects against damage totubesheet ligaments and adjacent tubesheet joints, extending the life of your heatexchanger and reducing total operating cost. Operating pressures to 1,000 psi (68.9Bar). Tube sizes for 0.472 ″ to 2.067 ″ (11.99mm to 52.50mm) I.D. tubes. Helium leaktight to 1 x 10 -11 cc/sec. Larger sizes available. Removable for retubing. Manufacturedunder a quality system that meets ANSI N45.2, 10CFR50 App B, 10CFR21, andcertied to ISO9001. U.S. patent number 5,437,310.

Pop-A-Plug ® Boiler Tube PlugsReliably plug boiler tubes without welding, and the time consuming preheatingand post weld stress relieving on the weld inspections that go with it. The uniquebreakaway controls installation force to ensure a positive seal without damage to tubeand tube-to-tubesheet joints. Operating pressures to 1,000 psi (68.9 Bar). Sizes for1.579 ″ to 1.823 ″ (40.11mm to 46.30mm) I.D. tubes. Larger sizes available on request.Helium leak tight to 1 x 10 -11 cc/sec. Use in either water or re tube boilers. Ideal forHRSG’s. Manufactured under a quality system that meets ANSI N45.2, 10CFR50 AppB, 10CFR21, and certied to ISO9001. U.S. patent number 5,437,310.

Pop-A-Plug ® Tube StabilizersEffectively stabilizes weakened or fractured heat exchanger and condenser tubes.Ideal for any type of shell and tube heat exchanger from high pressure feedwaterheaters to surface condensers. Sizes to t tubes ranging from 0.501 ″ to 0.960 ″ I.D.(12.73mm to 24.38mm). Available in either rod or cable type conguration. Available inany length.

Vibra Proof Condenser Plugs A metal, expandable elastomer condenser plug, ideal for temporary pluggingapplications. Available for tube I.D. ranges from 0.280 ″ to 1.309 ″ (7.11mm to33.25mm). Maximum pressure rating is 150 psi (10.3 Bar). Brass or stainless steel with

elastomers of neoprene, silicone, or uoroelastomer.

HEAT EXCHANGER TUBE PLUGS

DID YOU

KNOW?| http://estgroup.cwfc.com


5/16800.355.7044

Close Quarters Ram (CQ Ram)The Close Quarters Ram lets you install Pop-A-Plugs ® even when there’s only minimalclearance around the tube end. Ideal for tubes in the outermost row of tubes of closedhead feedwater heaters, or in tubes adjacent to a pass partition, or divider plates.

Pop-A-Plug ® Manual Installation Tool (MIT)Providing fast, reliable installation in situations where no air or electricity are available.

Each MIT comes complete with a Pull Rod and Positioner to install the size and stylePop-A-Plug ® identied in the tool’s model number. By interchanging pull rods andplug positioners, the MIT body can be used to install P2’s up to 1.160 ″ and CPI/PermaPlugs™ up to 1.149 ″ . The MIT can be used with manual wrenches or sockets, as wellas with electric or pneumatic impact wrenches.

Pop-A-Plug ® System Ram PackagesThere is no better way to install Pop-A-Plugs ® than with our hydraulic installationequipment. Our small and large ram packages are designed to hydraulically installPop-A-Plugs ® in seconds. The rams are compact, lightweight and easy to use. InstallsPop-A-Plug ® tube plugs quickly, safely and easily. Ram packages include a hydraulicram, pump, pressure gauge, high pressure hose, and a metal storage tool box.

Brush KitsTube preparation is vital to successful tube plugging. EST Group’s full complementof unique tube preparation brushes deliver fast, consistant tube preparation. Tubepreparation brushes size the hole and make it round, quickly remove leak causingsurface defects, and provide a roughened surface, improving the Pop-A-Plug’s ® pressure holding capability and leak tight integrity.

Pop-A-Plug ® Removal Tool (PRT)Quickly and easily remove installed Pop-A-Plugs ® with the Removal Tool. A dualfunction tool, the PRT features a nose piece that threads into the pin of an installedplug, enabling you to drive the pin from the ring. The tool retains the pin while aserrated spear grabs the ring’s I.D. An integral slide hammer then lets you pull out thering and pin in one operation.

Pull Rod AssembliesEST Group maintains a signicant inventory of Pull Rod assemblies, Channel Headassemblies and extensions for both near end and Through-The-Tube Plugging™applications.

INSTALLATION AND REMOVAL TOOLS


6/16

G-150 / G-150A Tube TestersDesigned to pneumatically test individual heat exchanger tubes for leaks. Either the entire tube bundle or an isolatednumber of tubes in the bundle can be tested using standard plant air supplies. Interchangeable seal and washer setsallow the G-150’s to test tube I.D. sizes from 0.28 ″ to 1.23 ″ (7.1mm to 31.2mm). The larger G-150A testing guns willoperate on tube I.D. sizes to 2.50 ″ (63.5mm). The G-150 tube testing gun set includes one G-150 air injection gunand one G-150 tube plugging gun. The G-150 air injection gun and G-150 plugging guns weigh less than 2.4 lbs.each. Replacement seal and washer sets, channel head extensions, and digital gauges are also available.

G-250 Vacuum Tube TesterDesigned to quickly seal off and evacuate individual heat exchanger tubes to test the tube for leakage. The G-250set is supplied with a vacuum test gun, plugging tool, and two sizes of interchangeable conical seal and washersets in a compact toolbox. The seal and washer sets allow the G-250 to be utilized to test heat exchanger tubeI.D.s ranging from 0.28 ″ to 1.45 ″ (7.1mm to 36.8mm). The G-250 gun is machined from high strength aluminum alloyreducing the fatigue associated with heavier testing equipment. Each G-250 set weighs less than 2.5 lbs (1.1kg).Optional seal set is available to test tubes to 2.50 ″ (63.5mm). Replacement seal and washer sets, channel headextensions, and digital gauges are also available.

HEAT EXCHANGER TUBE TESTERS

| http://estgroup.cwfc.com


7/16800.355.7044

G-450 Tube TesterDesigned to allow testing of straight tube heat exchangers when access is restricted to one end of the tube. Idealfor testing tubes in oating head heat exchanger applications with the tube bundles in place. The G-450 utilizesstandard plant air supplies. Its interchangeable support rod, tube extension assemblies, and seal and washer setsallow the G-450 to test tube I.D. sizes from 0.5 ″ to 1.23 ″ (12.7mm to 31.2mm). Digital gauges are also available.

G-650 Vacuum Tube Joint TesterDesigned to quickly test expanded tube-to-tubesheet joints for leakage. Ideal for heat exchanger manufacturersor companies performing retubing operations. The G-650 gun seals the tube I.D. and the tubesheet face, thenevacuates the tube end at the joint. A loss of vacuum indicates a leaky tube joint. The G-650 gun operates onstandard plant air supplies. A highly efcient venturi typically creates 21 to 24 in-Hg (707 to 808 mBar) vacuum onan inlet air supply of 100 psi (6.8 Bar) and 10 SCFM. Interchangeable manifolds, and seal and washer sets allowthe G-650 to test tube-to-tubesheet joints on 3/8 ″ to 1¼ ″ (9.5mm to 31.8mm) O.D. tubes. The larger G-650A JointTesting Gun will accommodate tube O.D. sizes from 1½ ″ to 2½ ″ (38.1mm to 63.5mm). The G-650 guns are notsuitable for testing excessively belled / ared tube ends, or tubes with welded tube-to-tubesheet joints. Digitalgauges are also available.

HEAT EXCHANGER TUBE TESTERS


8/16

EST Field Services provides a complete range of on-site servicesfor your shell and tube heat exchangers, condensers and oilcoolers. We also provide hydrostatic testing services for pipe, pipingsystems, and ange connections. Our trained service technicianshave the experience and know-how to handle the most demanding

jobs, safely, competently and on-time. We can quickly respondand meet the tightest repair schedules. Join our growing list ofsatised customers in the nuclear and fossil power generation,chemical, petrochemical, oil rening, pharmaceutical, industrial gas,shipbuilding, and boiler manufacturing industries.

Services• Tube Inspection and Testing• Pipe and Pressure Vessel Inspection and Hydrostatic Testing• Training• Tube Cleaning• Tube Sleeving, Lining, and Plugging• Tube Removal• Retubing

| http://estgroup.cwfc.com

EST FIELD SERVICES


9/16

HYDROSTATIC TEST & ISOLATION PLUGS

GripTight ®

High pressure pipe testing is safer than ever before. Unlike other plugs that can loosen and eject under highpressure, even becoming dangerous projectiles, the GripTight ® high pressure test plug actually uses test pressureto grip and seal more securely against the pipe’s inner diameter. The greater the pressure, the greater the grip!The result is a quicker installation, better sealing, and all around safer testing. Operating pressures to 13,900 psi(960 Bar), depending on plug size. Sizes from 1 ″ to 24 ″ (23.6mm to 603.0mm) in stock. Larger sizes through 42 ″ (1066.8mm) available. For smaller sizes, see the SQ2 test plugs.

DID YOU

KNOW?EST Group offers safety gags and pipe restraints for test plugs. Safety gags indicateexcessive movement of GripTight ® high pressure test plugs during hydro testing. Piperestraints clamp to the O.D. of a tube or pipe to act as secondary plug restraints during apressure test. Contact Customer Service for more information.

Double Block and BleedThe DBB plugs allow an operator to positively isolate and monitor potentially explosive vapors during hot work, theneffectively hydro test the new weld connection with one easy-to-use tool. The aluminum/steel construction makesthe tool highly portable, and easy to position. The volume of water required for testing is so small that testing canbe accomplished using a simple hand pump. This greatly facilitates testing in remote areas of the facility. ¾ ″ through24 ″ in STD wall, schedule 40 and 80 pipe sizes. Other sizes available. Pressure rated to 2,250 psi (155.1 Bar). Backpressure rated to 10 psi (0.7 Bar).

800.355.7044


10/160 | http://estgroup.cwfc.com

Reverse Pressure GripTight ®

The RPGT is the solution to the growing concern over inadequate longitudinal stress when testing welded angeconnections. By isolating the test area between a test ange and our RPGT plug, the weld joint is subjected to bothradial and longitudinal stresses during hydrostatic testing. Operating pressures to 2,250 psi. Available in sizes 2 ″ to 12- larger sizes also available. 4 ″ and larger plugs provide up to 0.5 ″ (12.7mm) pipe clearance.

High Lift Flange WeldThe High Lift Flange Weld test plug lets you monitor downstream conditions, isolate and purge the weld area,perform the weld, and hydro test the weld joint with one easy tool. No blind anging upstream, no vacuum truckfor evacuating the line, and no X-raying. Each test requires less than 2 gallons of water, and there is no need toll the entire line. You will use less water and minimize your environmental liabilities. Operating pressures to ANSIB16.5 requirements. Pipe sizes from ¾ ″ to 24 ″ (DN20 to DN600). Larger sizes also available. Flange classes 150 to600 lb. Higher classes available. All ange types. High Lift seal design provides improved seal-to-pipe clearance.



11/16


SQ2High pressure testing is faster and easier, thanks to the SQ2 high pressure test plugs.The twin cone design allows our SQ2 plugs to be easily installed and removed withoutcausing extensive damage to the pipe wall surface. Operating pressures to 6,500 psi(446 Bar). Sizes from 0.47 ″ to 0.93 ″ (11.9mm to 23.6mm). Shown with an optionalthread protector.

Auto GripTight ® Testing System (GTA)The AutoGT testing system speeds the plug installation and testing process.The system hydraulically energizes the test plug by simply activating a hydraulicpump, which eliminates the need for manually tightening the plug. Ideal for testing

applications in pipe or tubing I.D.’s ranging from 0.50″

to 4.34″

(12.7mm to 110.2mm)and operating pressures to 13,900 psi (960 Bar). Contact Customer Service and let ushelp you design a system.

Socket Weld (SQS)SQS test plugs are designed to facilitate testing socket weld ttings and couplings.During installation, the grippers expand within the socket holding the plug in positionwhile the seal element expands and seals off the bore of the tting. Designed for ASTM

A105 3000 LB carbon steel socket weld ttings. Sizes to t ½ ″ through 2 ″ ttings,operating pressures to 5,000 psi, depending on plug size. Larger sizes available. Shownwith thread protector.

O.D. GripTight ®

The O.D. GripTight ® uses EST Group’s patented self-gripping, self-sealing designand reliable dual seal mechanism to provide unparalleled speed and safety in hydro-testing. The GripTight ® design grips and seals along the pipe O.D. Since pipe O.D.’sare constant, one O.D. plug often replaces several different sizes of I.D. sealing plugsproviding an economic advantage and lower inventory. Operating pressures to 5,000psi (343 Bar). ¼ ″ to 4 ″ ANSI pipe sizes. ½ ″ to 3½ ″ tube sizes. Metric pipe and tubingsizes available.

800.355.7044 |

EST Group offers pipe caps for all test plug models and vents for GripTights ®. Caps allowported test plug designs to act as blind plugs. Vents help vent air or gases through plugsas the vessel or piping system is being lled for testing. Contact Customer Service for moreinformation.

DID YOU

KNOW?


12/162 | http://estgroup.cwfc.com


Threaded Pipe StoppersPorted hand tightened stoppers provide a face seal on NPT threaded connectionswithout the use of sealants or hand tools. NPT size ranges from 1/8 ″ to 4 ″ . Operatingpressure ratings vary by size and range, from 500 to 5,000 psi (34.5 to 344.7 Bar).

EST Field Services offers piping system and pressure vessel hydrostatic testing andinspection. EST Field Services also provides on-site training courses for all EST Groupproducts. Contact EST Field Services for more information.

DID YOU

KNOW?

Economy The Economy low pressure test plugs are designed for simple and reliable testing ofpipe and tubing, without the tube wall damage associated with other test plugs. That’sbecause our Economy plugs features a neoprene seal - the only part of the plug thatcomes in contact with the tube I.D. Simply install the Economy test plug into the openend of a pipe and tube tighten the wingnut (2 ″ to 4 ″ sizes use a hex nut) to expand theseal. Begin pressure testing. Operating pressures to 35 psi (2.4 Bar), depending onplug size. Sizes for 3/8 ″ to 4 ″ (11.2mm to 101.6mm).

Bolt TypeThe Bolt Type medium pressure test plugs are designed for simple and reliable testingof pipe and tubing, without the tube wall damage associated with other test plugs.Our Bolt Type plugs feature a neoprene seal - the only part of the plug that comes in

contact with the tube I.D. To use, simply install into the open end of the pipe or tubeand tighten the large compression nut to expand the seal element; then begin testing.Operating pressures to 250 psi (17.2 Bar), depending on the plug size. Sizes for 0.28 ″ to 10½ ″ (7.11mm to 266.7mm). Shown with thread protector.

GripTight ® PENo more having to square and round pipe ends to fuse on end caps. Just slip theGripTight ® PE plugs in the open ends of a section of pipe, tighten, and begin testing.Testing can be performed on an installed pipe or while it is still on the spool. Availablein 2 ″ , 3 ″ , 4 ″ , 6 ″ , and 8 ″ pipe sizes (DN50 to DN200). Plug sizes to cover 9 to 17 SDRapplications in either HDPE or MDPE pipe - other sizes available. Patented dual sealdesign. Conservatively rated to 150% of maximum operating pressure required under49 CFR 192.513. Shown with thread protector.


13/16

Tri-LightThe Tri-Light isolation plug allows you to quickly isolate open pipe ends whileperforming hot work. The triple seal design creates three separate contact pointswhile sealing against the pipe wall, affording your pipe crew a considerably safer workenvironment. With its one man installation, the Tri-Light speeds up pipe modicationsand repairs. Its vented design allows monitoring of upstream conditions.

Inatable Stoppers: Round, Cylindrical, and PillowUsed to seal gas lines, water lines, purge and containment. Available in sizes from 2 ″

to 72″

(DN 50 to DN 2400), depending on model stopper selected. Operating pressureratings from 1 to 69 psi (0.07 to 4.8 Bar), depending on size and style selected.

Medium Pressure Inate-A-Plug A medium pressure ported test plug, ideal for testing and plugging sewer lines,storm drains, pipe lines, and cooling water intakes. Features an aluminum body withan inatable seal. Nominal pipe sizes from 4 ″ to 36 ″ (DN 100 to DN 900). Mediumpressure rating to 100 psi (6.9 Bar).

Low and Medium Pressure Rim BoltLow and medium pressure ported test plugs. Typical uses include vent plugs, purgeplugs, or nite caps. Sizes from 8 ″ to 36 ″ (DN 200 to DN 900). Operating pressures to70 psi (4.8 Bar) but vary depending upon size and style.

Wing Nut A low pressure, low cost ported test plug. Nominal pipe sizes from 2 ″ to 12 ″ (DN 40 toDN 600). Operating pressures to 10 psi (0.7 Bar), depending on the plug size.

800.355.7044 |



14/16

P SeriesIdeal for hydro testing heat exchanger tubes, pipe and pressure vessels in the eldor in the shop. Available in a number of output pressures ranging from 2,500 to10,000 psi (172.3 to 689.4 Bar). All stainless steel water side. Easy to read 4 ″ (100mm) diameter pressure gauge. Completely enclosed in a lockable aluminum tool box.Supplied with 10ft (3.1 m) high pressure hose with quick couplings for air and waterinlet connections.

Blue Max 3Suitable for all hydrostatic testing applications. Available in a number of outputpressures ranging from 1,000 to 10,000 psi (68.6 to 686.3 Bar). Higher pressuresavailable. The Blue Max pumps features include all stainless steel high pressure sides

and an easy to read 4″

diameter pressure gauge. It’s self-contained in a tool box thathas storage for hose, ttings and plugs. It’s also supplied with mating quick connectcouplings for air inlet, water inlet and high pressure outlet connections.

HYDROSTATIC TEST PUMPS

Q Series A fully self-contained and portable hand pump for testing tubes, pipes, or variouspressure vessels. It is integrated into a 5 gallon attached resevoir which is easilyrelled. The pump is hand operated, which eliminates the need for compressed air.With the turn of a knob, the pressure output can be adjusted to either 1,000 psi, 2,000

psi, or 3,000 psi for the appropriate application. It has a silicone-lled gauge for allweather use and minimal moving parts for durability and longevity. High pressurebleed valve and hose with swivel tting included.

4 | http://estgroup.cwfc.com


15/16800.355.7044 |

DutchFinger ® Valve Changing Tools: O-Series, TBD Series, FPT SeriesThe O-Series is used to repair or replace a full port ball or gate valve while underpressure. Pipe sizes range from ½ ″ to 4 ″ (DN 15 to DN 100). Pressure ratings 200 to15 psi (13.8 to 1 Bar). The TBD Series is used to repair full port ball or gate valves inpiping systems under medium pressure. It incorporates a seal and a gripper to lockitself into position. Pipe sizes range from 1 ″ to 4 ″ . Pressure ratings are from 600 to 250psi (41.4 to 17.2 Bar), depending on size. The FPT Series is used to repair and replacefull port ball or gate valves on tanks and headers. This is an ideal tool to replaceleaking tank bottom valves. Available in size ranges from 2 ″ to 10 ″ (DN 50 to DN 250).Pressure ratings are from 600 to 250 psi (41.4 to 17.2 Bar), depending on size.

DutchFinger ® Watergate ToolsPrized by plumbers for simplifying soldering copper pipe. Available for ½ ″ to 4 ″ pipe sizes.

H-Series Hot Tap Kit Allows manual or power tapping of existing lines and extends service withoutshutting off existing pressure. Available in individual tools or a variety of kits from ½ ″ to 6 ″ (DN 15 to DN 150) line size. Max pressure for all tools is 150 psi (10.3 Bar).

D-Series Tapping ToolsIdeal for decontamination and disposal (D&D) work, D-Series Tapping Tools facilitatetapping, sampling and draining the contents of pipe and pressure vessels. Thelarge ¾ ″ NPT outlet on the tools’ body provides sampling and drainage port. Simplebolt-on installation – no welding or pyrotechnics are needed. All stainless steelconstruction with titanium nitride coated drill bit and GoreTex ® gaskets. Availablefor pipe sizes from ¼ ″ through 3 ″ at working pressures to 285 psi (19.7 Bar). Tubingsizes and larger pipe sizes are available.

PLUMBER’S & SPECIALTY TOOLS


16/16

North AmericaEST GroupCurtiss-Wright Flow Control2701 Township Line Road

Hateld, PA 19440-1770USA

(P) +1.215.721.1100 +1.800.355.7044(F) [email protected]://estgroup.cwfc.com

Europe / Middle-East / Africa (EMEA)EST Group B.V.

Hoorn 312a2404 HL Alphen aan den RijnThe Netherlands

(P) +31.172.418841(F) [email protected]

Asia PacicEST Group Asia35 Tannery Road#11-10 Tannery BlockRuby Industrial ComplexSingapore 347740

(P) +65.6745.8560(F) [email protected]

Product animations, instructions, and detailed technical informationare available on our website: http://estgroup cwfc com

Contact Information

heat exchanger leak repairs product information guide

Documents